Sole structure with proprioceptive elements and method of manufacturing a sole structure

ABSTRACT

A sole structure for an article of footwear comprises a midsole body having a proximal surface and a distal surface. Proprioceptive elements may extend in the hole in the midsole body, and translate toward the proximal surface in the holes upon a force directed along a central axis of the hole at a distal end of the proprioceptive elements. In various embodiments, the holes may angle relative to vertical from the proximal surface to the distal surface, the holes may be defined by perforations and the proprioceptive elements may be integral portions of the midsole body, or the midsole body may have a plurality of annular holes at the proximal surface, and a plurality of annular recesses in the distal surface, and a plurality of proprioceptive elements, each centered in a different annular hole of the plurality of annular holes. Methods of manufacturing articles of footwear are described.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.17/015,699, filed on Sep. 9, 2020, which is a divisional of U.S. patentapplication Ser. No. 15/958,120, filed on Apr. 20, 2018, now U.S. patentSer. No. 10/798,993, issued Oct. 13, 2020, which claims priority to, andthe benefit of, U.S. Provisional Application No. 62/488,512, filed Apr.21, 2017, each of which is hereby incorporated by reference in itsentirety.

TECHNICAL FIELD

The present teachings generally include a sole structure for an articleof footwear, and a method of manufacturing an article of footwear.

BACKGROUND

Footwear typically includes a sole structure configured to be locatedunder a wearer's foot to space the foot away from the ground. Solestructures in athletic footwear are configured to provide one or more ofdesired cushioning, motion control, and resiliency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom view of a sole structure for an article of footwearincluding a midsole having a midsole body and proprioceptive elements.

FIG. 2 is a bottom view of the midsole body of FIG. 1 with theproprioceptive elements removed.

FIG. 3 is an alternative embodiment in bottom view of a sole structurefor an article of footwear including a midsole having a midsole body andproprioceptive elements.

FIG. 4 is a lateral side view of the sole structure of FIG. 1 .

FIG. 5 is a medial side view of the sole structure of FIG. 1 .

FIG. 6 is a cross-sectional view of the sole structure of FIG. 2 takenat lines 6-6 in FIG. 2 and inverted relative to FIG. 2 .

FIG. 7 is a schematic illustration of the midsole body of FIG. 2 showinghinge areas of the midsole body at a cleft in the midsole body.

FIG. 8 is a perspective rear view of the midsole body of FIG. 2 showinga cleft in an open position.

FIG. 9 is a cross-sectional view of the midsole body of FIG. 2 at thelocation of the cross-section of FIG. 12 , and in an as-molded positionwith a cleft open.

FIG. 10 is a cross-sectional view of the midsole body of FIG. 2 at thelocation of the cross-section of FIG. 13 , and in an as-molded positionwith a cleft open.

FIG. 11 is a cross-sectional view of the midsole body of FIG. 2 at thelocation of the cross-section of FIG. 14 , and in an as-molded positionwith a cleft open.

FIG. 12 is a cross-sectional view of the midsole body taken at lines12-12 in FIG. 2 and inverted relative to FIG. 2 , with the cleft closed.

FIG. 13 is a cross-sectional view of the midsole body taken at lines13-13 in FIG. 2 and inverted relative to FIG. 2 , and in an as-moldedposition with the cleft closed.

FIG. 14 is a cross-sectional view of the midsole body taken at lines14-14 in FIG. 2 and inverted relative to FIG. 2 , and in an as-moldedposition with the cleft closed.

FIG. 15 is a cross-sectional and fragmentary view of an article offootwear including the sole structure of FIG. 1 , an outsole, and anupper.

FIG. 16 is a cross-sectional and fragmentary view of the midsole body ofFIG. 2 .

FIG. 17 is a fragmentary illustration in perspective view of theproprioceptive elements and a connecting web.

FIG. 18 is a cross-sectional and fragmentary view of the article offootwear of FIG. 15 and an object in phantom providing forces on some ofthe proprioceptive elements.

FIG. 19 is a bottom view of a sole structure for an article of footwearincluding an outsole with external flex grooves.

FIG. 20 is a plan view of the sole structure of FIG. 19 including amidsole with internal flex grooves.

FIG. 21 is a medial side view of the sole structure of FIG. 19 .

FIG. 22 is a cross-sectional view of the sole structure of FIG. 19 takenat lines 22-22 in FIG. 19 and inverted relative to FIG. 19 .

FIG. 23 is a cross-sectional view of a mold for a midsole.

FIG. 24 is a cross-sectional view of the mold of FIG. 23 , a mold toolincluding pins, and with a mold cavity filled with polymeric foam.

FIG. 25 is a flowchart of a method of manufacturing an article offootwear.

FIG. 26 is a bottom view of a sole structure for an article of footwearincluding a midsole having a midsole body and proprioceptive elements.

FIG. 27 is a bottom view of an alternative embodiment of a solestructure for an article of footwear, including the midsole body of FIG.26 .

FIG. 28 is a medial view of an article of footwear with the solestructure of FIG. 26 and including an upper.

FIG. 29 is a lateral view of the article of footwear of FIG. 28 .

FIG. 30 is a cross-sectional view of the article of footwear of FIG. 26taken at lines 30-30 in FIG. 26 and inverted relative to FIG. 26 .

FIG. 31 is a cross-sectional view of the article of footwear of FIG. 26taken at lines 31-31 in FIG. 26 and inverted relative to FIG. 26 .

FIG. 32 is a cross-sectional view of the article of footwear of FIG. 26taken at lines 32-32 in FIG. 26 and inverted relative to FIG. 26 .

FIG. 33 is a cross-sectional view of the article of footwear of FIG. 26taken at lines 33-33 in FIG. 26 and inverted relative to FIG. 26 .

FIG. 34 is a fragmentary plan view of a portion of the midsole body ofFIG. 26 showing perforations.

FIG. 35 is a fragmentary cross-sectional view of an article of footwearshowing a portion of the midsole body of FIG. 31 , and including anunderlying sock and an outsole.

FIG. 36 is a cross-sectional and fragmentary view of an article offootwear including the midsole of FIG. 27 , an inner sock, an outersock, and an outsole.

FIG. 37 is a schematic cross-sectional and fragmentary view of thearticle of footwear of FIG. 36 .

FIG. 38 is a schematic cross-sectional and fragmentary view of thearticle of footwear of FIG. 36 and an object in phantom providing forceson some of the proprioceptive elements.

FIG. 39 is a schematic cross-sectional and fragmentary view of anarticle of footwear with an alternative sole structure.

FIG. 40 is a flowchart of a method of manufacturing an article offootwear.

FIG. 41 is a plan view of an alternative embodiment of a sole structurefor an article of footwear.

FIG. 42 is a bottom view of the sole structure of FIG. 41 .

FIG. 43 is a cross-sectional view of the sole structure of FIG. 41 takenat lines 43-43 in FIG. 41 .

FIG. 44 is a fragmentary cross-sectional view of the sole structure ofFIG. 42 taken at lines 44-44 in FIG. 42 and inverted relative to FIG. 42.

FIG. 45 is a cross-sectional view of the sole structure of FIG. 41 takenat lines 45-45 in FIG. 41 .

FIG. 46 is a cross-sectional view of the sole structure of FIG. 41 takenat lines 46-46 in FIG. 41 .

FIG. 47 is a cross-sectional view of the sole structure of FIG. 45articulating at a proprioceptive element under a force along a centralaxis of the proprioceptive element.

FIG. 48 is a plan view of an alternative embodiment of a sole structurefor an article of footwear.

FIG. 49 is a bottom view of the sole structure of FIG. 48 .

FIG. 50 is a cross-sectional view of the sole structure of FIG. 48 takenat lines 50-50 in FIG. 48 .

FIG. 51 is a cross-sectional view of the sole structure of FIG. 48 takenat lines 51-51 in FIG. 48 .

FIG. 52 is a cross-sectional view of the sole structure of FIG. 48 takenat lines 52-52 in FIG. 48 .

FIG. 53 is a plan view of an alternative embodiment of a sole structurefor an article of footwear.

FIG. 54 is a bottom view of the sole structure of FIG. 53 .

FIG. 55 is a cross-sectional view of the sole structure of FIG. 53 takenat lines 55-55 in FIG. 53 .

FIG. 56 is a cross-sectional view of the sole structure of FIG. 53 takenat lines 56-56 in FIG. 53 .

FIG. 57 is a cross-sectional view of the sole structure of FIG. 53showing only the outsole and taken at the same lines as FIG. 56 .

FIG. 58 is a cross-sectional view of the sole structure of FIG. 53 takenat lines 58-58 in FIG. 53 .

FIG. 59 is a cross-sectional and fragmentary view of an article offootwear including the sole structure of FIG. 55 , an upper, and asockliner.

FIG. 60 is a cross-sectional and fragmentary view of the article offootwear of FIG. 59 .

FIG. 61 is a top view of the sockliner of FIG. 59 .

FIG. 62 is a flowchart of a method of manufacturing an article offootwear.

DESCRIPTION

A sole structure for an article of footwear comprises a midsole bodyhaving a proximal surface and a distal surface. The midsole body has afirst set of holes extending through the midsole body from the proximalsurface to the distal surface, a second set of holes extending throughthe midsole body from the proximal surface to the distal surface, and acleft extending partway through the midsole body between the first setof holes and the second set of holes. The center axes of holes of thefirst set are parallel with center axes of holes of the second set withthe cleft open, and are nonparallel with the center axes of the holes ofthe second set with the cleft closed. Accordingly, as discussed herein,the cleft allows the midsole body to be manufactured via a relativelysimple manufacturing process, using straight pins while enablingdifferent sets of angled holes angling in different directions in thefinished article of footwear.

In an embodiment, the cleft is in the proximal surface and extends alonga longitudinal axis of the midsole body. The first set of holes may bedisposed between a medial periphery of the midsole body and the cleft,and the second set of holes may be disposed between a lateral peripheryof the midsole body and the cleft. In such an embodiment, the centeraxes of the holes of the first set angle laterally outward from theproximal surface of the midsole body to the distal surface of themidsole body such that a distal end of each hole of the first set isnearer to the medial periphery than is a proximal end of the hole, andthe center axes of the holes of the second set angle laterally outwardfrom the proximal surface of the midsole body to the distal surface ofthe midsole body such that a distal end of each hole of the second setis nearer to the lateral periphery than is a proximal end of the hole.

In an embodiment, the midsole body is a polymeric foam and includes aninterior portion, and a skin that covers the interior portion. The skinextends along each hole of the first set and each hole of the second setfrom the proximal surface to the distal surface. The skin has a firstdensity, and the interior portion has a second density less than thefirst density such that the midsole body has a greater compressivestiffness under a force of the midsole body along the center axis ofeach hole than transverse to the center axis. Because the holes areformed in the mold via the molding process rather than a secondaryprocess, the skin lines the holes. The holes can be angled incorrespondence with expected directions of forces in the sole structure,thus utilizing the properties of the skin to increase compressivestiffness in reaction to the forces.

In an embodiment, the sole structure includes a plurality ofproprioceptive elements. Each proprioceptive element is disposed in adifferent hole of the first set or of the second set, and istranslatable relative to the midsole body along a central axis of therespective hole in a direction toward the proximal surface under a forcealong the central axis at a distal end of the proprioceptive element. Inthis manner, the proprioceptive elements provide sensory feedback to awearer regarding the position of an object, such as a ball, on the solestructure.

In an embodiment, a connecting web is integral with the plurality ofproprioceptive elements at either proximal ends or distal ends of theplurality of proprioceptive elements such that the connecting web andthe plurality of proprioceptive elements are a single, unitarycomponent. In such an embodiment, the connecting web may be integralwith the plurality of proprioceptive elements at proximal ends of theplurality of proprioceptive elements. The connecting web lifts away fromthe midsole body with any ones of the plurality of proprioceptiveelements that translate relative to the midsole body in a directiontoward the proximal surface. The connecting web advantageously enablesthe interconnected proprioceptive elements to be disposed in therespective holes of the midsole body simultaneously. In otherembodiments without a connecting web, the proprioceptive elements can bedisposed in the respective holes individually.

In an embodiment, a sock overlies the connecting web such that theproximal ends of the plurality of proprioceptive elements translate intoa foot-receiving cavity of the sock. In the same or a differentembodiment, an outsole is secured to the distal surface of the midsolebody. The outsole may be integral with the plurality of proprioceptiveelements at distal ends of the plurality of proprioceptive elements.

In an embodiment, one or more of the plurality of proprioceptiveelements is cylindrical or discoid. The proprioceptive elements mayinclude silicone proprioceptive elements disposed in at least one of thefirst set of holes or the second set of holes at a heel region of themidsole body. The first set of holes may include holes having differentdiameters. Additionally, the second set of holes may include holeshaving different diameters. One or more holes of the first set may havea different diameter than one or more holes of the second set.Alternatively or in addition, at least one or more holes within thefirst set may have a different diameter than one or more other holes ofthe first set. Alternatively or in addition, at least one or more holeswithin the second set may have a different diameter than one or moreother holes of the second set. Accordingly, the proprioceptive elementsmay be of different sizes and diameters.

In an embodiment, the first set of holes and the second set of holes aredisposed in one or both of a bottom portion or a sidewall portion of themidsole body, and in at least one of a forefoot region, a midfootregion, or a heel region of the midsole body.

A method of manufacturing an article of footwear comprises disposingpolymeric material into a mold cavity of a mold for a midsole body. Themold has a mold surface with a protrusion. The method includes extendinga first set of pins into the mold cavity on a first side of theprotrusion, and a second set of pins into the mold cavity on a secondside of the protrusion. The pins of the first set are parallel with thepins of the second set. The method includes molding the polymericmaterial to the shape of the mold surface, thereby forming a midsolebody, the first set of pins forming a first set of holes in the midsolebody, the second set of pins forming a second set of holes in themidsole body, and the protrusion forming a cleft between the first setof holes and the second set of holes. The method further includeswithdrawing the first set of pins and the second set of pins from themidsole body, and removing the midsole body from the mold. Center axesof the holes of the first set of holes are parallel with center axes ofthe holes of the second set of holes when the cleft is open, andnonparallel with the holes of the second set when the cleft is closed.

The method may include disposing a first plurality of proprioceptiveelements in at least some holes of the first set of holes, and a secondplurality of proprioceptive elements in at least some holes of thesecond set of holes such that any of the first plurality and the secondplurality of proprioceptive elements translate relative to the midsolebody in a direction toward the proximal surface under a force along thecentral axes of the proprioceptive elements at the distal ends. Thefirst plurality of proprioceptive elements may have a first density, andthe second plurality of proprioceptive elements may have a seconddensity different than the first density.

In an embodiment, a connecting web is integral with the first pluralityof proprioceptive elements and with the second plurality ofproprioceptive elements at proximal ends of the first plurality and thesecond plurality. In such an embodiment, disposing the first and secondsets of proprioceptive elements in at least some of the holes of thefirst set and the second set includes positioning the connecting webover the proximal surface of the midsole body such that the firstplurality of proprioceptive elements and the second plurality ofproprioceptive elements are aligned with respective holes of the firstset and the second set, and inserting the first plurality ofproprioceptive elements and the second plurality of proprioceptiveelements simultaneously.

In an embodiment, the method may further comprise securing an outsole tothe distal surface of the midsole body, with the outsole spanning acrossthe first set of holes and the second set of holes and across distalends of the first plurality of proprioceptive elements and the secondplurality of proprioceptive elements.

In an embodiment, the method may further comprise securing an elasticsockliner layer to the proximal surface of the midsole body, with theelastic sockliner layer spanning across the first set of holes and thesecond set of holes.

In an embodiment, the method may further comprise securing an inner sockto the proximal surface of the midsole body, and securing an outer sockto the distal surface of the midsole body such that the midsole body isdisposed inside of the outer sock, and between the inner sock and theouter sock.

Within the scope of the present teachings, an article of footwearcomprises a sole structure, including a midsole body having a proximalsurface and a distal surface. The midsole body has a first set of holesextending through the midsole body from the proximal surface to thedistal surface, a second set of holes extending through the midsole bodyfrom the proximal surface to the distal surface, and a cleft extendingpartway through the midsole body between the first set of holes and thesecond set of holes. Center axes of holes of the first set are parallelwith center axes of holes of the second set with the cleft open, and arenonparallel with the center axes of the holes of the second set with thecleft closed.

In an embodiment, the article of footwear further comprises a pluralityof proprioceptive elements, each proprioceptive element disposed in adifferent hole of the first set or of the second set, and translatablerelative to the midsole body along a central axis of the respective holein a direction toward the proximal surface under a force along thecentral axis at a distal end of the proprioceptive element.

A sole structure for an article of footwear comprises a midsole bodywith a proximal surface and a distal surface. The midsole body hasperforated holes established by perforations through the midsole body.The sole structure further includes a plurality of proprioceptiveelements, each proprioceptive element disposed in a different one of theperforated holes as an integral portion of the midsole body surroundedby the perforations. Each proprioceptive element is movable relative tothe midsole body along a central axis of the proprioceptive element in adirection toward the proximal surface under a force along the centralaxis at a distal end of the proprioceptive element. In an embodiment,the midsole body includes multiple flexible arms extending from each ofthe plurality of proprioceptive elements between the perforations.

In an embodiment, the perforated holes are disposed in one or both of abottom portion or a sidewall portion of the midsole body, and in atleast one of a forefoot region, a midfoot region, or a heel region ofthe midsole body. One or more of the plurality of proprioceptiveelements may be cylindrical or discoid. At least some of the holes mayhave different diameters.

The sole structure may further comprise at least some punched holesextending through the midsole body from the proximal surface to thedistal surface. At least some of the punched holes may be empty.

In an embodiment, an inner sock is disposed inside of an outer sock, andthe midsole body is disposed inside of the outer sock, and between theinner sock and the outer sock. The proximal surface of the midsole bodyis secured to a distal surface of the inner sock, and the distal surfaceof the midsole body is secured to a proximal surface of the outer sock.

A method of manufacturing an article of footwear may compriseperforating holes in a midsole body such that the perforated holesextend through the midsole body and define a plurality of integralproprioceptive elements, each proprioceptive element disposed in adifferent one of the perforated holes as an integral portion of themidsole body surrounded by perforations. Each integral proprioceptiveelement is movable relative to the midsole body along a central axis ofthe proprioceptive element in a direction toward the proximal surfaceunder a force along the central axis at a distal end of theproprioceptive element.

The method may further comprise punching out multiple ones of theperforated holes at the perforations such that a plurality of punchedthrough-holes extend from the proximal surface to the distal surface.The method may further comprise disposing a plurality of proprioceptiveelements in the punched through-holes, each of the plurality ofproprioceptive elements disposed in a different one of the punchedthrough-holes. The plurality of proprioceptive elements may have adensity different than a density of the midsole body.

In an embodiment, the punched through-holes may include a first set ofpunched through-holes in a forefoot region of the midsole body, and asecond set of punched through-holes in a heel region of the midsolebody. At least some of the plurality of proprioceptive elements disposedin the first set of punched through-holes may have a different densitythan at least some of the plurality of proprioceptive elements disposedin the second set of punched through-holes.

The method may further comprise securing an elastic sockliner layer tothe proximal surface of the midsole body, with the elastic socklinerlayer spanning across the punched through-holes. In the same or adifferent embodiment, the method may further comprise securing anoutsole to the distal surface of the midsole body.

The method may further comprise securing an inner sock to the proximalsurface of the midsole body, and securing an outer sock to the distalsurface of the midsole body such that the midsole body is disposedinside of the outer sock, and between the inner sock and the outer sock.

A sole structure for an article of footwear comprises a midsole bodywith a proximal surface and a distal surface. The midsole body has aplurality of annular holes at the proximal surface, and a plurality ofannular recesses in the distal surface. Each annular recess encircles adifferent annular hole of the plurality of annular holes from below, andextends beyond a lowest extent of the annular hole toward the proximalsurface. The midsole body also has a plurality of proprioceptiveelements, each centered in a different annular hole of the plurality ofannular holes. Each proprioceptive element translates along a centralaxis of the proprioceptive element in a direction toward the proximalsurface under a force along the central axis at a distal end of theproprioceptive element such that the midsole body articulates at theproprioceptive element.

In an embodiment, at least one of the plurality of proprioceptiveelements has a height less than a depth of the annular hole in which theproprioceptive element is centered. In the same or a differentembodiment, at least one proprioceptive element of the plurality ofproprioceptive elements has a height greater than a depth of the annularhole in which the proprioceptive element is centered.

In an embodiment, the sole structure further comprises an outsolesecured to the distal surface of the midsole body and lining theplurality of annular recesses. The outsole has a proximal surface withannular protrusions nested in the annular recesses of the midsole body.The outsole may be further secured to distal ends of the plurality ofproprioceptive elements. In an alternative embodiment, the outsole mayhave through-holes that are aligned with and underlie the plurality ofproprioceptive elements such that each of the plurality ofproprioceptive elements is exposed at a distal surface of the outsole.

In an embodiment, the outsole has external flex grooves at a distalsurface of the outsole and extending between adjacent ones of theplurality of proprioceptive elements. The external flex grooves mayextend along lines connecting center axes of the adjacent ones of theplurality of proprioceptive elements.

The sole structure may further comprise a sockliner overlying themidsole body. The sockliner may include an elastic layer overlying theplurality of proprioceptive elements. The sockliner may further includea foam layer between the elastic layer and the midsole body. The foamlayer may have holes aligned with the plurality of proprioceptiveelements such that the plurality of proprioceptive elements extendthrough the foam layer toward the elastic layer. The elastic layer is aninnermost layer of the sole structure. The elastic layer is in directcontact with the proximal end of each of the plurality of proprioceptiveelements. The outsole is secured to the distal surface of the midsolebody. The outsole includes a plurality of annular protrusions. Thedistal surface of the midsole body includes a plurality of midsolerecessed surface portions each defining one of the plurality of annularrecesses. Each of the plurality of annular recesses includes one of theplurality of midsole recessed portions. The outsole has an outsoledistal surface and an outsole proximal surface opposite the outsoledistal surface. The outsole proximal surface includes a plurality ofoutsole protruded surface portions each defining one of the plurality ofannular protrusions and each directly connected to a different one ofthe midsole recessed surface portions so that the outsole lines each ofthe plurality of annular recesses. Each of the plurality of annularprotrusions includes one of the plurality of protruded outsole surfaceportions. The outsole distal surface includes a plurality of outsolerecessed surface portions each being opposite to a respective one of theplurality of outsole protruded surface portions. Each of the pluralityof proprioceptive elements has a proximal end opposite the distal end.Each of the plurality of proprioceptive elements has a side surfaceinterconnecting the proximal end and the distal end. The outsoleproximal surface of the outsole is secured to the side surface of eachof the plurality of proprioceptive elements.

The sole structure may be in combination with an upper and a strobelsecured to the upper. The strobel may be secured to the proximal surfaceof the midsole body and may have holes aligned with the holes of thefoam layer and with the plurality of proprioceptive elements such thatthe plurality of proprioceptive elements protrudes through both theholes of the strobel and the holes of the foam layer when interfacingwith the elastic layer.

A method of manufacturing an article of footwear comprises forming amidsole body such that the midsole body has annular holes in a proximalsurface of the midsole body, and annular recesses in a distal surface ofthe midsole body. Each annular recess encircles a different one of theannular holes from below and extends beyond a lowest extent of thedifferent one of the annular holes toward the proximal surface. Themidsole body as formed also includes a plurality of proprioceptiveelements, each proprioceptive element centered in a different one of theannular holes.

The method may further comprise securing a sockliner to the proximalsurface of the midsole body. The sockliner may have a plurality of holesthat align with the plurality of proprioceptive elements such that theplurality of proprioceptive elements extends through the plurality ofholes in the sockliner.

The method may further comprise securing an elastic sockliner top layerto the proximal surface of the sockliner, with the elastic sockliner toplayer spanning across the plurality of holes of the sockliner such thatthe plurality of proprioceptive elements protrudes through the holes ofthe sockliner when interfacing with the elastic sockliner top layer.

The method may further comprise securing a strobel to the proximalsurface of the midsole body. The strobel has holes that align with theplurality of proprioceptive elements. The method may also comprisesecuring a sockliner to the proximal surface of the strobel. Thesockliner has holes that align with the plurality of proprioceptiveelements. The method may also comprise securing an elastic sockliner toplayer to a proximal surface of the sockliner, with the elastic socklinertop layer spanning across the holes of the sockliner such that theplurality of proprioceptive elements protrudes through the holes of thestrobel and the holes of the sockliner when interfacing with the elasticsockliner top layer.

In an embodiment, the method further comprises securing an outsole tothe distal surface of the midsole body. The outsole lines the annularrecesses of the midsole body. The outsole may have through-holes.Securing the outsole may include aligning the through-holes of theoutsole with the plurality of proprioceptive elements such that theplurality of proprioceptive elements is exposed at a distal surface ofthe outsole.

An article of footwear comprises a sole structure including a midsolebody with a proximal surface and a distal surface. The midsole body hasperforated holes established by perforations through the midsole body.The midsole body also has a plurality of proprioceptive elements, eachproprioceptive element disposed in a different one of the perforatedholes as an integral portion of the midsole body surrounded by theperforations and movable relative to the midsole body along a centralaxis of the proprioceptive element in a direction toward the proximalsurface under a force along the central axis at a distal end of theproprioceptive element.

A sole structure for an article of footwear comprises a midsole bodyhaving a proximal surface and a distal surface, and an outsole having aproximal surface and a distal surface. The proximal surface of theoutsole is secured to a distal surface of the midsole body. The outsoleincludes external flex grooves at the distal surface of the outsole, andthe midsole body includes internal flex grooves at the proximal surfaceof the midsole body. The internal flex grooves overlie and are alignedwith the external flex grooves such that the sole structure articulatesat the external flex grooves both in dorsiflexion and in plantarflexion.

The above features and advantages and other features and advantages ofthe present teachings are readily apparent from the following detaileddescription of the modes for carrying out the present teachings whentaken in connection with the accompanying drawings.

Referring to the drawings, wherein like reference numbers refer to likecomponents throughout the views, FIG. 1 is a bottom view of a portion ofa sole structure 10 for an article of footwear 12 shown in FIGS. 4 and15 . FIG. 1 shows a midsole 14 of the sole structure 10. The midsole 14includes a midsole body 32 with a plurality of holes 34 that open at theproximal surface 22. The midsole body 32 may be a polymeric foammaterial that provides cushioning and support. In the embodiment shown,the holes 34 are through-holes that extend from the proximal surface 22of the midsole body 32 to a distal surface 23 of the midsole body 32.The distal surface 23 is shown in the bottom view of FIG. 1 and isindicated in FIG. 6 .

The midsole 14 also includes a plurality of proprioceptive elements 36disposed in some of the holes 34 such that they are translatable in theholes 34 as described herein. The proprioceptive elements 36 areindicated with dot shading for clarity. Distal ends 38 of theproprioceptive elements 36 are shown. FIG. 2 shows the midsole 14 priorto installation of the proprioceptive elements 36 in the holes 34. Aflexible outsole 16 (shown in phantom in FIG. 4 and in cross-sectionalview in FIG. 15 ) and an upper 18 (shown in FIG. 4 ) are not shown inFIG. 1 .

The sole structure 10 is one of many embodiments of sole structuresdisclosed herein that include proprioceptive elements that enhance awearer's awareness of an object in contact with the article of footwear,and of the location of contact of the object on the article of footwear.For example, a midsole with proprioceptive elements as discussed hereinimproves proprioceptive feedback (i.e., tactile feedback), which mayenhance ball control in ball sports, such as soccer. The sole structuresdisclosed herein may also have enhanced ability to grip a ball, such asdue to protrusions of distal ends of the proprioceptive elements at adistal surface of the outsole, and/or due to the ability of the outsoleand midsole to flex together both during dorsiflexion andplantarflexion. Other features and advantages of the various embodimentsof sole structures with proprioceptive elements are set forth in thediscussion herein.

With reference to FIG. 4 , the article of footwear 12 includes an upper18 secured to the sole structure 10. In the embodiment shown, the upper18 is a sock construction, such as a bootie, and may be a unitary,360-degree knit material that has a distal surface 20 secured to aproximal surface 22 of the sole structure 10 (best shown in FIG. 6 ).The upper 18 thus wraps under a foot 24 received in a foot-receivingcavity 17 of the upper 18, and includes an underfoot portion 26 (seeFIGS. 6 and 15 ) in lieu of a strobel. Alternatively, the upper 18 mayterminate at a lower periphery that is secured to a strobel, with thestrobel secured to the sole structure 10 similar to upper 618 in FIG. 60. In some embodiments, both a strobel having holes aligned with theholes 34 in the midsole body 32, and a sockliner having holes alignedwith the holes in the strobel may overlay the midsole 14. An upper layerof the sockliner may directly overlay the proprioceptive elements 36between the foot 24 and the proprioceptive elements 36. FIG. 60 showssuch an upper layer 635, which is a relatively thin, flexible,elastically-stretchable material, such as a four-way stretch fabric.However, in the sole structure 10 of FIG. 1 , the midsole body 32 has athickness sufficient such that a sockliner is not used. In anotheralternative embodiment, the midsole body 32 could be placed between aninner sock and an outer sock, as described with respect to the midsolebody 232 of FIGS. 37-39 .

In some embodiments, the proprioceptive elements may be integrallysecured to or formed as a unitary, one-piece component with a sockliner,with the proprioceptive elements extending downward therefrom into theholes of the midsole body. In still other embodiments, theproprioceptive elements could be integrally secured to or formedintegrally with a connecting web (i.e., a flat, flexible layerinterconnected with the proprioceptive elements) and extend therefrominto the holes of the midsole body from the proximal side of the midsolebody so that all of the proprioceptive elements can be handled togetherin unison via the connecting web. The connecting web can be secured atselect locations to the proximal surface of the midsole (or, in someembodiments, to the distal surface of the midsole body) such thattranslation of the proprioceptive elements as described herein is notunduly limited. For example, the web may be left disconnected from themidsole surface at regions around each of the proprioceptive elements.

In still other embodiments, the proprioceptive elements could beintegrally secured to or formed integrally with the outsole such thatthe proprioceptive elements extend into the holes of the midsole bodyfrom a proximal surface of the outsole. In still other embodiments, theproprioceptive elements could be separate from one another, each havinga flange at its distal end or proximal end. The midsole body could havecorresponding recesses that receive the flange such that theproprioceptive elements extend into the holes. These recesses could beeither in the proximal surface or the distal surface of the midsolebody. If on the proximal side, the recesses could be configured with adepth corresponding to a thickness of the flange such that the proximalsurface of the flange is flush with the proximal surface of the midsolebody when received in the recess.

As best shown in FIG. 15 , the proprioceptive elements 36 are disposedin the holes 34 such that they are not secured to and are translatablerelative to the interior walls 44 of the midsole body 32 within theholes 34. The midsole body 32 thus serves as a frame that carries theproprioceptive elements 36. Each proprioceptive element 36 is disposedin a different one of the holes 34. All of the holes 34 may contain aproprioceptive element 36, or some of the holes 34 may be left empty,such that they do not have a proprioceptive element 36 in them. FIG. 1is an embodiment in which only some of the holes 34 contain aproprioceptive element 36. FIG. 3 is an alternative embodiment of a solestructure 10B with a midsole 14B including midsole body 32 and in whicheach hole 34 contains a proprioceptive element 36.

In the embodiment shown, the proprioceptive elements 36 are integrallyformed with a connecting web 25 as a unitary, one-piece component, asbest shown in FIGS. 15, 17, and 18 . Proximal ends 42 of theproprioceptive elements 36 are integral with the web 25, while distalends 38 extend into the holes 34 and rest at or above the proximalsurface of the outsole 16, which is exposed at the bottom of each hole34. The distal surface of the upper 18 is secured to the proximalsurface 27 of the web 25. Alternatively, the proprioceptive elements 36could be integrally formed in the same way with a sockliner, inembodiments in which a sockliner is used. In that case, no web would beincluded, as the sockliner would be positioned in place of the web, andwould connect all of the proprioceptive elements 36. In yet anotherembodiment, the connecting web 25 could be removed in FIG. 15 , and thedistal ends 38 could be integrally formed with the outsole 16. Theproximal ends 42 could then extend upward toward the upper 18 in theholes 34, without connection to any other component.

The proprioceptive elements 36 are narrower than the holes 34. Stateddifferently, the diameters of the proprioceptive elements 36 are lessthan the diameters of the holes 34. Accordingly, the proprioceptiveelements 36 are spaced apart from the interior walls 44 of the holes 34,or at least are not secured thereto such that they are movable relativeto the walls 44. As best shown in FIG. 18 , each proprioceptive element36 is movable relative to the midsole body 32 along a central axis CA ofthe proprioceptive element 36 in a direction toward the proximal surface22 of the midsole body 32 when under a force F along the central axis ata distal end 38 of the proprioceptive element 36. In FIG. 18 , theforces F on the proprioceptive elements 36 are due to a ball 40 underthe sole structure 10 being controlled by the wearer. The ball 40 is onthe ground, and trapped between the ground and the wearer's foot 24 bythe article of footwear 12. The translation of the proprioceptiveelements 36 under the forces F causes the proximal ends 42 of some ofthe proprioceptive elements 36 to be pressed toward the foot 24 relativeto the midsole body 32 at the proximal surface 22. More specifically,those ones of the proprioceptive elements 36 that are subjected toforces by the ball 40 will translate relative to the midsole body 32 inthis manner, and may be considered active for the particular ballposition. The flexible connecting web 25 at the active proprioceptiveelements 36 will also translate toward the foot 24 under the force ofthe translating proprioceptive elements 36. The flexible connecting web25 is secured to the proximal surface 22 of the midsole body 32, but notin a small region directly surrounding each of the proprioceptiveelement 36. This enables the connecting web 25 to lift away from themidsole body 32, if necessary, with the translating, activeproprioceptive elements 36. For example, a circular region of the distalsurface 29 of the connecting web 25 may be freely movable relative to(i.e., not bonded to) the proximal surface 22 of the midsole body 32.The connecting web 25 may be bonded to the midsole body 32 at otherlocations not within those regions (i.e., further from eachproprioceptive element 36). Other proprioceptive elements 36 not incontact with the ball 40 do not experience the same degree oftranslation, and may be considered inactive for the particular ballposition. The inactive proprioceptive elements 36 will not be pressedtoward the foot 24, or at least not to as great an extent as the activeproprioceptive elements 36. This dichotomy between active and inactiveproprioceptive elements will be sensed by the wearer. The proprioceptiveelements 36 are thus tactile components that act as sensory indicatorsto the wearer of the position of the ball 40 relative to the foot 24,enhancing ball control.

At least some of the proprioceptive elements 36 may have a differentdensity than the midsole body 32 so that they are compressible relativeto the midsole body 32 along their central axes. The midsole body 32 mayhave a first density, and the proprioceptive elements 36 may have asecond density less than the first density. Alternatively, the seconddensity may be greater than the first density. Some or all of theproprioceptive elements 36 may be more dense than the midsole body 32,or some or all may be less dense than the midsole body 32. Some or allcould also have the same density as the midsole body 32.

In embodiments discussed herein, the proprioceptive elements may begenerally compressed under the weight of the wearer when the outsole ofthe sole structure is on the ground. When the foot is lifted, however,and the sole structure is used to control a ball, the magnitude ofloading on the sole structure is generally lower than when supportingthe full weight of the wearer, such that the proprioceptive elementshave a greater ability to translate relative to the midsole body 32 thanwhen fully loaded, enhancing the proprioceptive feedback to the wearerat each proprioceptive element during ball handling.

As best shown in FIG. 15 , the proprioceptive elements 36 may bereferred to as plugs, and are disposed in the holes 34 but spaced apartfrom the interior walls 44 of the midsole body 32 that define the holes.Accordingly, the proprioceptive elements 36 do not in fact plug theholes. The holes 34 are cylindrical in shape, and the proprioceptiveelements 36 may also be cylindrical. As shown, the proprioceptiveelements 36 are elongated, with a length greater than their width.Depending on the thickness of the midsole body 32, some of the holes 34could have a width greater than their length, in which case theproprioceptive element 36 disposed in that hole 34 may be a cylinderthat is discoid (i.e., has a width greater than its length). In someembodiments, the proximal ends 42 and/or the distal ends 38 of theproprioceptive elements 36 may have a rounded shape or a conical shape,in which case only the midsection of the proprioceptive element iscylindrical. In an embodiment in which the proximal ends 42 and thedistal ends 38 are flat, the entire proprioceptive element 36 iscylindrical.

With reference to FIG. 2 , the midsole body 32 is shown as having holes34 in each of a forefoot region 50, a midfoot region 52, and a heelregion 54 of the midsole body 32. In other embodiments, the holes 34 maybe disposed in only one of or any two of the forefoot region 50, themidfoot region 52, and the heel region 54. Each hole 34 has a distalopening 37, also referred to as a distal end 37, at the distal surface23 of the midsole body 32. The distal ends 37 of the holes 34 are theends shown in the bottom view of FIG. 2 , for example. Each hole 34 alsohas a proximal opening 39, also referred to as a proximal end 39, at theproximal surface 22 of the midsole body 32 such that each hole 34 is athrough-hole. FIG. 8 indicates the proximal ends 39 of the holes 34. Theholes 34 are disposed in both of a bottom portion 60 (FIG. 2 ), a medialsidewall portion 62 (FIG. 5 ), and a lateral sidewall portion 64 (FIG. 4) of the midsole body 32. In other embodiments, holes 34 may be providedonly in the bottom portion 60, or only in one or both of the sidewallportions 62, 64.

The size, location, and angle of the center axis CA of a hole 34relative to vertical V (see FIG. 12 ), as well as whether or not aproprioceptive element 36 is disposed in the hole 34 all contribute tothe cushioning and proprioceptive sensory feedback of the midsole 14. Asshown, the holes 34 have a variety of different diameters. In general,the midsole body 14 can provide greater cushioning at a hole 34 with alarger diameter than a hole 34 with a smaller diameter, due to theability of the surrounding foam to collapse into the hole 34 underloading, assuming no proprioceptive element 36 is disposed in the hole34. The collapse of the midsole body 32 into an empty hole 34 when underforces not aligned with the central axis CA of the hole 34 is indicatedin FIG. 16 .

The proprioceptive elements 36 may be disposed in regions at which ballhandling is expected to occur. For example, in some sports, the forefootregion 50 and the heel region 54 may be used for ball handling more thanthe midfoot region 52. The forefoot region 50 and the heel region 52 maybe used for rolling the ball underfoot, while the midfoot region 52 maybe used more often for trapping the ball. Accordingly, proprioceptiveelements 36 provided in the forefoot region 50 and the heel region 54may be most useful for proprioception. In the embodiment of FIG. 1 ,forefoot proprioceptive elements 36 are shown in some of the holes 34 ofthe forefoot region 50, and heel proprioceptive elements 36 are shown insome of the holes 34 of the heel region 54. Holes 34 in the midfootregion 52 are empty (i.e., they contain no proprioceptive elements 36).The holes 34 containing proprioceptive elements 36 in the forefootregion 50 may be referred to as a first set of holes, and the holes 34containing proprioceptive elements 36 in the heel region 54 may bereferred to as a second set of holes 34. The proprioceptive elements 36in the forefoot region 50 of FIG. 1 may have a density greater than orless than the density of the midsole body 32. In one embodiment,proprioceptive elements 36 are provided only in the forefoot region 50and are a foam material that has a greater density than the material ofthe midsole body 32. Proprioceptive elements are also disposed in holes34 in the heel region 54, and may be configured for impact cushioning aswell as proprioception. For example, the proprioceptive elements 36 inthe heel region 54 may be silicone. In some embodiments, aproprioceptive element 36 may completely fill a hole 34 and act as aplug. For example, proprioceptive elements 36 used in the heel region 54for cushioning could be such plugs.

The midsole body 32 may be polymeric foam that is compression-moldedaccording to a thermal process, with the holes 34 formed during themolding process rather than via a secondary process. All outer surfacesof a molded foam article, such as a molded midsole body 32, may have anouter skin 66 that is denser than an interior portion 68 of the midsolebody 32 due to contact with the surfaces of the mold tools. The outerskin 66 of the midsole body 32 is indicated in FIG. 16 , and isseparated from the interior portion 68 by a representative boundary 70.Forming the holes 34 during molding via pins, as disclosed herein, willcause the interior walls 44 of the holes 34 to also have the dense outerskin 66. More particularly, the midsole body 32 includes an interiorportion 68, and a skin 66 that covers the interior portion 68 andextends along each of the holes 34 from the proximal surface 22 to thedistal surface 23. In a non-limiting example, the interior portion 68may be an open-cell foam, or a closed-cell foam. In an open-cell foam,air moves out of the cell when the foam is compressed. Accordingly, thecompressive stiffness of the foam is unaffected by the air in the cells.In a closed-cell foam, air is trapped in the cell, and compresses whenthe foam is compressed, thus affecting the compressive stiffness of thefoam. The skin 66 has a first density, and the interior portion 68 has asecond density less than the first density. Reference to a seconddensity of the interior portion 68 may be numerically different than thesecond density of the proprioceptive elements 36 discussed herein, asfirst and second densities are relative terms used in comparison to twodifferent components. The denser skin 66 forms a cylinder around eachhole 34, bordering the hole 34 beginning at the interior wall 44 andextending into the midsole body 32 away from the interior wall 44 ashort distance, forming an annular cylinder around the hole 34. A skinhaving a greater thickness will provide greater resistance tocompression than a thinner skin. Conversely, a skin with a lesserthickness will allow the foam of the midsole around the holes tocompress to a greater extent under a given load than a thicker skin. Thecylinder of skin 66 around the hole 34 is most resistant to compressionalong its length, as the full length of the stiffer skin 66 must becompressed. The midsole body 32 thus has a greater compressive stiffnessunder loading along the center axis CA of a hole 34 than under loadingtransverse to the center axis CA, or than under loading at an obliqueangle to the center axis CA (i.e., angles greater than zero degrees andless than 90 degrees). An empty hole 34, or a hole containing aproprioceptive element 36 of a lesser density than the midsole body 32,will provide cushioning and absorb forces that are not aligned with thecenter axis of a hole 34 by a partial or complete collapse of the foammidsole body 32 into the hole 34, as shown in FIG. 16 . Forces alignedwith the center axis CA, however, will be at least partially counteredby the resistance of the tunnel-like skin 66 at the hole 34, resistingcompression.

As further discussed herein, the holes 34 are angled relative to avertical axis V indicated in FIGS. 12 and 18 . The angle A of thecentral axis CA of a hole 34 relative to the vertical axis V may beselected so that the central axis CA aligns with an expected directionof loading force on the midsole body 32 at the location of the hole 34,such as the expected direction of impact forces during walking orrunning, or from making a lateral movement, such as a cutting movementduring sports. For example, in certain sports, lateral (i.e., sideways)cutting motions are common. Angles of holes 34 at the lateral sidewall64 and/or the medial sidewall 62 may be selected to coincide with thelateral forces typically resulting from a lateral cutting motion.

In order to provide angled holes 34 with an outer skin 66 along thewalls 44 of the midsole body 32 bordering the holes 34, the midsole body32 is molded with a cleft 72 in the proximal surface 22 so that themidsole body 32 is in a “split open” position (referred to herein as amolded position), as shown in FIG. 8 . In the embodiment shown, thecleft 72 extends along a longitudinal axis L of the midsole body 32. Inother embodiments, a mold could be configured to provide a cleft thatextends transversely. With a longitudinally-extending cleft 72 as shownin FIG. 8 , when the cleft 72 is closed (as shown in FIG. 12 ), theresulting angled holes angle laterally-outward from the proximal surface22 to the distal surface 23. In the open, molded position of the cleft72 in FIG. 8 , the central axes CA of the holes 34 extend vertically,and the center axes CA of the holes of the first set 76 are parallelwith the center axes CA of the holes of the second set 78. As shown inFIG. 8 , a first set 76 of holes 34 is disposed between a medialperiphery 77 of the midsole body 32 and the cleft 72, and a second set78 of holes 34 is disposed between a lateral periphery 79 of the midsolebody 32 and the cleft 72. The proximal openings 39 of the first set 76are disposed at a first portion of the proximal surface 22, and theproximal openings 39 of the second set 78 are disposed at a secondportion of the proximal surface 22. The first set 76 of holes 34 may bereferred to as a medial set 76, and the second set 78 of holes 34 may bereferred to as a lateral set 78. The midsole body 32 is hinged at thecleft 72. Stated differently, the cleft 72 extends downward from theproximal surface 22 only partway to the distal surface 23 at least insome regions, such that a first portion 32A (e.g., a medial portion) ofthe midsole body 32 with the medial set 76 of holes 34 is connected to asecond portion 32B (e.g., a lateral portion) of the midsole body 32 atleast at connected portions referred to as a forefoot hinge FH and aheel hinge HH at the bottom of the cleft 72. FIG. 7 is a schematicdepiction of the midsole body 32 if pressed even further open at thecleft 72 than the molded position of FIG. 8 , so that the forefoot hingeFH and the heel hinge HH are apparent. The cleft 72 may extendcompletely through the midsole body 32 in some areas, such that themedial portion 32A and the lateral portion 32B may be completely splitand disconnected from one another at an area rearward of the heel hingeHH, at an area forward of the forefoot hinge FH, and at an area betweenthe forefoot hinge FH and the heel hinge HH, as shown in FIG. 7 . Thisallows the distal surface 23 to curve upward toward the foremost extentof the midsole body 32 at the forefoot portion 50 forward of theforefoot hinge FH, the distal surface 23 to curve upward toward therearmost extent rearward of the heel hinge HH, and the distal surface 23to curve upward at the midfoot portion 52 between the heel hinge HH andthe forefoot hinge FH.

FIGS. 9-11 show the midsole body 32 in the molded position with thecleft 72 open. The cleft 72 is shown as having an angle A betweenvertical V and each of its sidewalls 72A, 72B in the open (as molded)position. The sidewalls 72A, 72B are also indicated in FIG. 8 . Theangle A may be, for example 40 degrees, so that a total opening betweenthe sidewalls of the cleft 72 is 80 degrees. Accordingly, when the cleft72 is closed, as shown in FIGS. 12-14 , the angled holes 34 will eachextend laterally outward at angle A, which is 40 degrees in theembodiment shown. The angle of the holes 34 is best shown in thecross-sectional views of FIGS. 12, 13, 15 and 18 . The center axes CA ofthe holes 34 of the first set 76 angle laterally outward from theproximal surface 22 to the distal surface 23 such that a distal end 37of each hole 34 of the first set 76 is nearer to the medial periphery 77than is a proximal end 39 of the hole 34. The center axes CA of theholes 34 of the second set 78 angle laterally outward from the proximalsurface 22 to the distal surface 23 such that a distal end 37 of eachhole 34 of the second set 78 is nearer to the lateral periphery 79 thanis a proximal end 39 of the hole 34. The center axes CA of the holes 34of the first set 76 are parallel to one another in the open (as-molded)position of the cleft 72 (see FIG. 9 ), and the center axes CA of theholes 34 of the first set 76 are nonparallel with the center axes CA ofthe holes 34 of the second set 78 in the closed position of the cleft 72(see FIG. 12 ).

As shown in FIGS. 12-14 , the first portion 32A of the midsole body 32is contiguous with the second portion 32B at the proximal surface 22 andat the distal surface 23 when the cleft 72 is closed. In other words,there are no gaps or differences in elevation between the first portion32A and the second portion 32B at the cleft 72 when the cleft is closed.The cleft 72 may be kept in the closed position by thermally bonding oradhering the sidewalls 72A, 72B to one another. Alternatively, thebonding of an upper at the proximal surface 22 or an outsole at thedistal surface 23 may serve to retain the cleft 72 in the closedposition.

In embodiments having a connecting web 25, the web 25 may be positionedover midsole body 32 with the cleft 72 in the open position, and theintegral proprioceptive elements 36 may be inserted into the holes 34effectively simultaneously simply by moving the connecting web 25 towardthe proximal surface 22 with the proprioceptive elements 36 aligned withthe holes 34. The web 25 may be stretchable such that it is pulledtransversely to stretch across the cleft 72 during insertion, andretracts to a narrower width corresponding to the narrower width at theproximal surface 22 of the midsole body 32 with the cleft 72 in theclosed position. Alternatively or in addition, a portion of theconnecting web 25 extending over the cleft 72 may be folded into thecleft 72 prior to closing the cleft 72, such that the web 25 is bondedin the cleft 72. In either instance, the web 25 with integralproprioceptive elements 36 simplifies the insertion process for theproprioceptive elements 36, allowing insertion simultaneously or nearlysimultaneously simply by aligning the proprioceptive elements 36 withthe holes 34 when the cleft 72 is positioned over the midsole body 32,and then lowering the proprioceptive elements 36 into the holes 34. Ininstances where the holes 34 and the corresponding proprioceptiveelements 36 are a variety of sizes, this saves assembly time and reducesthe potential for erroneously inserting the differently-sizedproprioceptive elements 36 in the wrong holes 34. In other embodiments,however, where no web or other connecting layer (e.g., sockliner,outsole) for the proprioceptive elements 36 is used, the proprioceptiveelements 36 can be individually and separately inserted into thecorresponding holes 34, as they will be trapped between the outsole 16and the upper 18 or other overlying layer in any event once the articleof footwear 12 is assembled.

In FIG. 15 , the outsole 16 is shown with a proximal surface 80 securedto the distal surface 23 of the midsole body 32. In lieu of outsole 16,an outsole 16A with flex grooves 82 in a distal surface 83 of theoutsole 16A may be used, as shown in the sole structure 10A of FIGS. 19,21, and 22 . Only some of the flex grooves 82 are labeled in FIG. 19 .The outsole 16A is shown secured to a midsole body 32C that does notshow holes with proprioceptive elements, but could instead be secured tothe midsole body 32. The flex grooves 82 would extend between adjacentones of at least some of the proprioceptive elements 36 when secured tomidsole body 32. In FIG. 20 , the proximal surface 22A of the midsolebody 32C is shown with internal flex grooves 84. The internal flexgrooves 84 overlie and are aligned with the external flex grooves 82.More specifically, internal flex grooves 84 are arranged in a patternmatching the pattern of the external flex grooves 82 so that theinternal flex grooves 84 border either side of centerlines of theexternal flex grooves 82, as best indicated in FIG. 22 . In other words,two internal flex grooves 84 extend parallel to one another, trackingthe grooves 82 from above, with a narrow portion of the midsole body 32Cbetween each of the internal flex grooves 84 directly overlying theexternal flex grooves 82. Accordingly, the internal flex grooves 84 andthe external flex grooves 82 allow the midsole body 32C and outsole 16Ato function as pleated bellows at the grooves 82, 84 such that the solestructure 10A articulates at the external flex grooves 82 and theinternal flex grooves 84 both in dorsiflexion (e.g., along curve 85) andin plantarflexion (e.g., along curve 86) of the sole structure 10A, asbest depicted in FIG. 22 . Curve 85 represents a degree of articulationat which at least some of the internal flex grooves 84 will close. Curve86 represents a degree of plantar flexion at which at least some of theexternal flex grooves 82 will close. The longitudinally-extending flexgrooves 82, 84 allow articulation in the transverse direction of thesole structure 10A as well, such as during plantarflexion over a curvedball surface.

FIGS. 23-24 show a representative mold 90 for manufacturing the midsolebody 32. FIG. 25 is a flowchart of a method of manufacturing the midsolebody 32 using the mold 90 of FIGS. 23-24 . The mold 90 includes an uppermold half 90A and a lower mold half 90B. The upper mold half 90A has anupper mold surface 91A in a mold cavity 92, and the lower mold half 90Bhas a lower mold surface 91B in the mold cavity 92. The mold halves 90A,90B are movable toward one another to the closed position shown in FIGS.23 and 24 , in which the mold surfaces 91A, 91B together form a moldcavity 92. The mold halves 90A, 90B are movable away from one another toopen the mold cavity 92 (e.g., by moving mold half 90A upward in FIG. 23, moving mold half 90B downward, or both, as will be understood from thepresent disclosure to those skilled in the art. The upper mold surface91A includes a protrusion 93 that extends toward the lower mold half90B. The lower mold half 90B also includes a protrusion 94. Bothprotrusions 93, 94 run along a longitudinal axis of the mold 90, whichis perpendicular to the plane of the cross-section shown. The protrusion93 forms the cleft 72 shown in the midsole body 32 in FIG. 8 , and theprotrusion 94 molds the distal surface 23 of the midsole body 32 to theopen position. In certain regions, the protrusions 93, 94 may touch.Such regions will correspond to the areas where the cleft 72 extendscompletely through the midsole body 32, where the medial portion 32A andthe lateral portion 32B are completely split and disconnected from oneanother (e.g., at an area rearward of the heel hinge HH, at an areaforward of the forefoot hinge FH, and at an area between the forefoothinge FH and the heel hinge HH, as described with respect to FIG. 7 ).

The upper mold half 90A has through-holes 95A, and the lower mold half90B has blind holes 95B. Alternatively, through-holes 95A may be used inlieu of blind holes 95B. The through-holes and blind holes 95A, 95B arealigned with one another to receive a first set of pins 96A, and asecond set of pins 96B, as shown in FIG. 24 . The pins 96A, 96B extendfrom a mold tool 97 that is translatable toward and away from the mold90. A single mold tool 97 is used. Alternatively, the first and secondsets of pins 96A, 96B may be secured to separate mold tools. The pins96A, 96B and the holes 95A, 95B are arranged in the same pattern (i.e.,relative spacing and size), which is identical to the pattern of theholes 34 in the midsole body 32.

FIG. 25 is a flowchart illustrating a method 100 of manufacturing anarticle of footwear, such as the article of footwear 12. In block 102,the method 100 includes extending a first set of pins 96A into themidsole cavity 92 on a first side of the protrusion 94 (i.e., on themedial side), and a second set of pins 96B into the midsole cavity 92 ona second side of the protrusion 94 (i.e., on the lateral side). Thefirst set of pins 96A forms the first set 76 of holes 34 in the midsolebody 32, the second set of pins 96B forms the second set 78 of holes 34in the midsole body 32, and the protrusion 93 forms the cleft 72 betweenthe first set 76 of holes and the second set 78 of holes, all shown inFIG. 8 . Center axes CP1 of the pins of the first set of pins 96A areparallel with center axes CP2 of pins of the second set 96B.

The method 100 includes block 104, disposing polymeric material 98 intoa mold cavity 92 of a mold 90 for a midsole body 32. For example, thepolymeric material 98 may be introduced through an injection port 99 ofthe mold 90. The method 100 continues with block 106, molding thepolymeric material to the shape of the mold surface, thereby forming amidsole body 32. Molding in block 106 may include compression,vacuum-forming, and/or thermal processing. In other embodiments, blocks102, 104, and 106 can be performed in a different order than asdescribed.

In block 108, the method 100 includes withdrawing the first set of pins96A and the second set of pins 96B from the midsole body 32. Because thepins 96A, 96B are parallel, the same mold tool 97 can be used to formthe first and second sets 76, 78 of holes 34 simultaneously.Additionally, because the holes 34 are formed during molding, ratherthan during a secondary process following molding, the skin 66 bordersthe less dense, interior portion 68 of the midsole body 32, providingcompression resistance to forces along the central axes of the holes 34,as discussed with respect to FIG. 15 .

In block 110, the method 100 includes removing the midsole body 32 fromthe mold 90. As described with respect to FIGS. 9, 12, 15 and 18 ,center axes CA of the holes 34 of the first set 76 of holes arenonparallel with center axes CA of the holes 34 of the second set 78 ofholes when the cleft 72 is closed.

In block 112, the method 100 may include disposing a first plurality ofproprioceptive elements 36 in at least some holes 34 of the first set 76and a second plurality of proprioceptive elements 36 in at least someholes 34 of the second set 78. In embodiments having a connecting web25, this may including placing the connecting web 25 above the midsolebody 32, and aligning the proprioceptive elements 36 with the holes 34.In embodiments in which the proprioceptive elements 36 are integrallyformed with another layer, such as a sockliner or an outsole, block 112will include placing the layer above (e.g., if the layer is a sockliner)or below (e.g., if the layer is an outsole) the midsole body 32, andaligning the proprioceptive elements 36 with the holes 34. Inembodiments in which each of the proprioceptive elements 36 isdisconnected from each of the other proprioceptive elements 36, block112 will include separately aligning and disposing each proprioceptiveelement 36 into a respective hole 34 of the correct size.

In one embodiment, a first set of proprioceptive elements 36 aredisposed in the forefoot region 50, and a second set of proprioceptiveelements 36 are disposed in the heel region 54. The first plurality ofproprioceptive elements may have a first density, and the secondplurality of proprioceptive elements may have a second density differentthan the first density. Additionally, the midsole body 32 may have adensity at the skin 66, and a different density at the interior portion68, both of which are different than the densities of the proprioceptiveelements 36. The proprioceptive elements 36 of the first set 76 may be apolymeric foam that has a density greater than or lesser than themidsole body 32. The proprioceptive elements 36 of the second set 78 maybe silicone.

Next, the method 100 may include block 113, securing an outsole, such asoutsole 16 or 16A described herein, to the distal surface 23 of themidsole body 32. In some embodiments, securing an outsole may occurlater in the method 100, such as after block 118 described herein. Ifblock 113 is performed following block 112, then the method 100 moves toeither of blocks 114 or 116. Block 114 includes securing an upper 18,such as a sock, to the proximal surface 22 of the midsole body 32. Inother embodiments, the method 100 includes block 116, securing anelastic sockliner layer to the proximal surface 22 of the midsole body32. The elastic sockliner layer may be, for example, elastic socklinerlayer 635 as described with respect to FIGS. 59-61 , with the elasticsockliner layer spanning across the first set 76 of holes 34 and thesecond set 78 of holes 34. In the embodiment of FIG. 15 , a sockliner isnot required, however, as the midsole body 32 has a thickness sufficientto also serve as a sockliner.

In still other embodiments, the method 100 moves from block 112 to block118, in which a distal surface of an inner sock is secured to theproximal surface 22 of the midsole body 32, and then in block 120, anouter sock is pulled over the midsole body 32 and secured to the distalsurface 23 of the midsole body 32 such that the midsole body 32 isdisposed inside of the outer sock, and between the inner sock and theouter sock. For example, although FIGS. 37-39 are illustrated withmidsole body 232, a sole structure including midsole body 32 can includean inner sock and an outer sock in a like manner. In such an embodiment,following block 120, the method 100 continues in block 122, securing anoutsole 16 to the distal surface of the outer sock, as shown anddescribed with respect to FIG. 37 .

FIG. 26 shows another embodiment of a sole structure 210A having amidsole 214A for an article of footwear 212. The sole structure 210Aincludes a midsole 214A with a midsole body 232. The midsole 214A may beused in the article of footwear 212 shown in FIGS. 37-39 in lieu ofmidsole 214.

The midsole body 232 has perforations 244 that extend from the proximalsurface 22 to the distal surface 23. In FIG. 26 , the distal surface 23is shown, but it is apparent that the perforations 244 extend entirelythrough the thickness of the midsole body 232 from the proximal surface22 to the distal surface 23. In the embodiment shown, the perforations244 define perforated shapes that are circular. The perforated shapesare integral portions 236 of the midsole body 232 and are surrounded bythree equally-spaced perforations 244. The integral portions 236 serveas proprioceptive elements 236. The three equally-spaced perforations244 define a perforated hole 234A. As best shown in FIG. 34 , arms 248span between the main portion 235 of the midsole body 232 (i.e., theportion surrounding the perforations 244) to secure the integralproprioceptive element 236 within the perforated hole 234A. A pluralityof proprioceptive elements 236 that are disposed in the plurality ofperforated holes 234A are thus integral portions of the midsole body 232surrounding the perforations 244. The perforations 244 and integralproprioceptive elements 236 may be formed during molding of the midsolebody 232, or the midsole body 232 may be perforated in a secondaryprocess, after molding.

The arms 248 enable some degree of translating movement of theproprioceptive element 236 relative to the surrounding main portion 235of the midsole body 232 along the central axis CA of the proprioceptiveelement 236 when a force is applied at a distal end 38 of theproprioceptive element 236 toward the proximal surface 22. Theproprioceptive elements 236 can thus provide tactile feedback to awearer, as described with respect to proprioceptive elements 36.

In some embodiments, such as is shown in FIG. 27 , some or all of theintegral proprioceptive elements 236 are punched out. Stateddifferently, multiple ones of the perforated shapes (i.e., the integralproprioceptive elements 236) are punched out at the perforations 244such that a plurality of punched through-holes 234B extend from theproximal surface 22 to the distal surface 23. The midsole body 232 withpunched-out holes 234B is referred to as midsole 214 and is included insole structure 210 of FIGS. 37-39 . In FIGS. 26-34 an outsole 16 isremoved for clarity in viewing the midsole 214. The midsole body 232,midsole 214, and sole structure 210 have many of the same features asmidsole body 32, midsole 14, and sole structure 10, and such featuresare referred to with like reference numbers and are as described withrespect to sole structure 10. Each of the punched through-holes 234B canthen have a proprioceptive element 36 inserted into the through-hole234B, in the same manner as described with respect to proprioceptiveelements 36 in through-holes 34 of FIG. 1 . The midsole body 232 mayhave a first density, and the inserted proprioceptive elements 36 mayhave a second density different than the first density, as describedwith respect to the midsole body 32 and sole structure 10. Differentproprioceptive elements 36 of different densities can be used, anddisposed in different regions of the midsole 232.

FIG. 27 shows many punched through-holes 234B with proprioceptiveelements 36 disposed therein. FIG. 27 also shows that some of theintegral proprioceptive elements 236 are not punched out. Additionally,FIG. 27 shows two of the punched through-holes 234B without anyproprioceptive elements 36 therein. In some embodiments, these or otherpunched through-holes 234B can be left empty (i.e., punched out withouta proprioceptive element 36 disposed therein in a secondary process).Accordingly, the midsole 214 may include a combination of: (i) integralproprioceptive elements 236 in perforated holes 234A formed duringmolding, three-dimensional printing, or otherwise forming of the midsole214 or perforated therein during a secondary process; (ii)proprioceptive elements 36 disposed in punched through-holes 234B in asecondary process; and (iii) empty, punched through-holes 234B.

As is evident in the embodiment of FIGS. 26-28 , the perforated holes234A are disposed in a bottom portion 60, and in a medial sidewallportion 62 of the midsole body 232, in the forefoot region 50, and themidfoot region 52. The heel region 54 and the lateral sidewall portion64 in the embodiment shown in FIGS. 26-29 generally have no perforatedholes 234A of other holes, but in other embodiments, perforated holes234A could be disposed in one or both of these portions as well.

At least some of the perforated holes 234A have different diameters, asshown in FIG. 26 . The integral proprioceptive elements 236 are discoid,as best shown in FIG. 34 . The proprioceptive elements 36 are alsodiscoid in the embodiment of FIG. 27 . The thickness of the midsole body232 is less than midsole body 32, so the proprioceptive elements 36 areless elongated than those in midsole 14 when disposed in the punchedthrough-holes 234 of midsole 214.

FIG. 30 shows the midsole body 232 taken at lines 30-30 in FIG. 26 .FIGS. 31, 32, and 33 are cross-sectional views of the midsole body 232of FIG. 26 . FIG. 34 is a plan view of the proximal surface 22 of themidsole body 232 at one of the perforated holes 234A.

FIG. 36 shows a fragmentary portion of the sole structure 210 includingthe midsole body 232, with an upper 218 that includes an outer sock 271secured to the distal surface 23. FIG. 36 shows the sole structure 210such as when unloaded (e.g., not subjected to the forces of controllinga ball). FIG. 37 is a longitudinal cross-sectional view. An outsole 16is secured to the distal surface of the outer sock 271. The distalsurface of an inner sock 273 may be secured at the proximal surface 22of the midsole body 232, as shown in FIG. 36 , or a relatively thin,elastic sockliner layer, such as a four-way stretch knit materialelastic layer 635 shown in FIG. 59 , may be secured so that it overliesthe holes 234A, 234B and the proprioceptive elements 236, 36. In eitherembodiment, the inner sock 273 or the elastic sockliner layer 635 isstretched by the translating proprioceptive elements 36, 236 toward thefoot-receiving cavity 17, such as shown and described in FIG. 38 whensubjected to forces along their central axes CA.

The inner sock 273 may be secured first by placing the inner sock 273 ona last, and then securing the midsole 214, including the midsole body232 and the proprioceptive elements 236 to the inner sock 273. The outersock 271 is then pulled over the inner sock 273 and midsole 214, and theproximal surface of the outer sock 271 is secured to the distal surface23. The midsole body 232 is disposed inside of the outer sock 271, andbetween the inner sock 273 and the outer sock 271.

FIG. 38 shows forces F due to a ball 40 on certain ones of theproprioceptive elements 36, 236, causing these proprioceptive elements36, 236 to be “active” and translate relative to the midsole body 232along the central axis CA of the respective holes 234B, 234A, whileinactive ones of the proprioceptive elements 36, 236 do not translate inthis manner. The active proprioceptive elements 36, 236 protrude furtherat the proximal surface 22 than when not under loading, and thus providetactile feedback of ball position to the foot 24 of the wearer. Therelatively thin and flexible outsole 16, outer sock 271, and inner sock273 do not interfere with the ability of the proprioceptive elements 36,236 to provide feedback in this manner.

In an alternative embodiment in FIG. 39 , only a single sock layer 271is used, and the proprioceptive elements 36 are integral with a sheet orconnecting web 275, similar to connecting web 25. The outsole 16 issecured to the webbing 275.

As an alternative to outsole 16, the outsole 16A of FIG. 19 could beused with the midsole body 232, and the midsole body 232 could haveinternal flex grooves 84 at the proximal surface 22 (similarly asdescribed with respect to midsole body 32C of FIG. 20 ) to enhancearticulation of the sole structure 210 both in dorsiflexion andplantarflexion.

FIG. 40 is a flowchart of a method 310 of manufacturing an article offootwear, such as article of footwear 212 and may apply to solestructure 210, 210A. The method 310 begins with block 312, perforating amidsole body 232 such that perforations 244 define a plurality ofperforated shapes and extend through the midsole body 232 from aproximal surface 22 to a distal surface 23, creating perforated holes234A. Perforating the midsole body 232 may be done during molding of themidsole body 232, in which case block 312 is a molding process.Alternatively, the midsole body 232 may be 3D printed, with theperforations created during the printing process by controlled materialdeposition. In another alternative, perforating the midsole body 232 maybe a secondary process, in which case a molding process occurs prior toblock 312.

The method 310 then proceeds with block 314, punching out multiple onesof the perforated shapes at the perforations 244 such that a pluralityof punched through-holes 234B extend from the proximal surface 22 to thedistal surface 23. Next, block 316 includes disposing proprioceptiveelements 36 in one or more of the punched through-holes 234B, eachproprioceptive element 36 disposed in a different one of the punchedthrough-holes. The proprioceptive elements 36 may have a densitydifferent than a density of the midsole body 232. In some embodiments,such as when manufacturing an article of footwear including solestructure 210A, blocks 314 and 316 are omitted, so that the midsole body232 includes only the perforated openings 234A, and the integralproprioceptive elements 236 are the only proprioceptive elements in themidsole body 232. In some embodiments, block 314 occurs, but block 316is omitted, so that all of the punched through-holes 234B remain empty.

In some embodiments, the punched through-holes 234B include a first setof punched through-holes in a forefoot region 50 of the midsole body232, and a second set of punched through-holes in a heel region 54 ofthe midsole body 232. The punched through-holes are not shown in theheel region in FIG. 24 , but their placement in the heel region 54 willbe readily understood by a person skilled in the art in light of thepresent disclosure. In such an embodiment, at least some of theproprioceptive elements 36 disposed in the first set of punchedthrough-holes 234B have a different density than at least some of theproprioceptive elements 36 disposed in the second set of punchedthrough-holes 234B. For example, the proprioceptive elements 36 in theforefoot region 50 may be a foam that has a greater or lesser densitythan the foam of the midsole body 232, and the proprioceptive elements36 in the heel region 54 may be silicon proprioceptive elements 36 forcushioning rather than or in addition to proprioception.

The method 310 then proceeds to block 318, securing a component layer tothe proximal surface 22 of the midsole body 232. For example, an elasticsockliner layer 635 such as in FIG. 61 or a sock 273 (which may be aninner sock or a single sock used without an outer sock) may be securedto the proximal surface 22 of the midsole body 232, spanning across thepunched through-holes 234B and the perforated holes 234A.

In embodiments having an inner sock 273 and an outer sock 271, themethod 310 proceeds to block 320, securing an outer sock 271 to thedistal surface 23 of the midsole body 232 such that the midsole body 232is disposed inside of the outer sock 271, and between the inner sock 273and the outer sock 271.

Next, the method 310 proceeds to block 322, securing an outsole 16 or16A to the distal surface 23 of the midsole body 232. In embodimentsthat do not include an outer sock 271 or other layer between the midsolebody 232 and the outsole, the method 310 may include completing block322 prior to block 318 so that the sole structure 210 is complete priorto securing the sockliner layer, the sock 271, or other upper componentto the midsole body 232.

FIGS. 41-47 show another embodiment of a sole structure 410 for anarticle of footwear. The sole structure 410 includes a midsole 414 witha midsole body 432 and proprioceptive elements 436. The sole structure410, midsole 414, midsole body 432, and proprioceptive elements 436 havemany of the same features as described with respect to sole structure 10and corresponding components thereof, and such features are referred towith like reference numbers and are as described with respect to solestructure 10.

The midsole body 432 has a proximal surface 22 and a distal surface 23indicated in FIG. 43 . The midsole body 432 has holes 434 that open atthe proximal surface 22. In the embodiment shown, the holes 434 are inthe forefoot region 50 and the midfoot region 52 at the bottom portion60 of the midsole 414. In other embodiments, the holes 434 could also bedisposed in a heel region 54, in medial or lateral sidewall portions, orboth. A plurality of proprioceptive elements 436 are integrally securedto the midsole body 432. In fact, the midsole body 432 and theproprioceptive elements 436 are a single, unitary component moldedintegrally with one another. Some of the proprioceptive elements 436 aregenerally cylindrical with rounded ends, and others are frustoconicalwith rounded ends.

The holes 434 are not through-holes, but instead are annular recesses inthe proximal surface 22 that surround the proprioceptive elements 436,as indicated in FIGS. 41 and 43 . The holes 434 have differentdiameters, as is apparent in FIG. 41 . The holes 434 are configured suchthat the proprioceptive elements 436 each have a height greater than adepth of the annular recesses at the proximal surface 22, as shown withrespect to proprioceptive elements 436 having height H and annularrecesses 434 having a depth D in FIG. 45 . Each proprioceptive element436 is disposed in a different one of the holes 434, and is partiallysurrounded by an interior wall 444 of the hole 434 when the solestructure is in the relatively unflexed position of FIG. 43 , withoutloading. The holes 434 at the proximal surface 22 may have differentdepths D, and the proprioceptive elements 436 may have different heightsH, but in the midsole 432, the height H of the proprioceptive element436 is greater than the depth D of the hole 434 for each proprioceptiveelement 436 and hole 434 in which it is disposed, where both the heightH and the depth D are measured from the bottom of the hole 434. In otherembodiments, some of the holes may have depths greater than the heightsof the proprioceptive elements that they surround, as illustrated withrespect to FIG. 50

The midsole body 432 also has annular recesses 437 in the distal surface23, each annular recess 437 encircling a different one of the pluralityof proprioceptive elements 436 from below, and aligned with one of theholes 434 in the proximal surface 22. Some of the annular recesses 437are indicated in FIGS. 43 and 45 . Each annular recesses 437 extendsupward from the distal surface 23 beyond a lowest extent of the hole 434that it surrounds.

The sole structure 410 includes an outsole 416 secured to the distalsurface 23 of the midsole body 432 and lining the annular recesses 437of the midsole body 43, as best shown in FIG. 43 . The outsole 416 has aproximal surface 453 with annular protrusions 455 nested in the annularrecesses 437 of the midsole body 432. The outsole also has annularrecesses 457 at a distal surface 483. The annular recesses 437 underliethe annular protrusions 455 and encircle the annular recesses 434 frombelow. The outsole 416 is further secured to distal ends 38 ofproprioceptive elements 436 (i.e., to a distal surface of eachproprioceptive element 436).

The outsole 416 has external flex grooves 482 at a distal surface 483 ofthe outsole 416 as best shown in FIG. 42 . The external flex grooves 482extend along lines connecting center axes CA of adjacent ones of theproprioceptive elements 436, as indicated in FIG. 42 . Only some of theexternal flex grooves 482 are indicated in FIG. 42 .

As illustrated by a comparison of FIG. 45 to FIG. 47 , eachproprioceptive element 436 is movable relative to adjacent portions 432Aof the midsole body 432 along a central axis CA of the proprioceptiveelement 436 in a direction toward the proximal surface 22 when under aforce toward the proximal surface 22 applied at a distal end 38 of theproprioceptive element along the central axis CA. As illustrated in FIG.47 , the annular recesses 437 of the midsole body 432 encircling theholes 434, and the protrusions 455 and annular recesses 457 of theoutsole 416 enable the sole structure 410 to function as bellows betweenthe proprioceptive element 436 and the portions 432A of the midsole body432 surrounding the hole 434, articulating to simultaneously decreasethe depths of the holes 434 and the annular recesses 457 while drivingthe proximal end 42 of the proprioceptive element 436 in the directionof the axial force, such as further toward a foot-receiving cavity and afoot therein to enhance proprioceptive feedback. The external grooves482 further enable independent articulation of the sole structure 410 atadjacent proprioceptive elements 436, such that a distinction betweenactive proprioceptive elements 436 and inactive proprioceptive elements436 is more apparent to the wearer. The sole structure 410 canarticulate both in dorsiflexion (e.g., along curve 85 in FIG. 43 ) andin plantarflexion (e.g., along curve 86 in FIG. 43 ) similar to solestructure 10A as described with respect to FIG. 20 .

FIGS. 48-52 illustrate another embodiment of a sole structure 510 with amidsole 514 having a midsole body 532. The outsole 416 as described withrespect to FIGS. 41-47 is secured to the midsole body 532 in the samemanner as described with respect to midsole body 432. The sole structure510 is identical in all respects to sole structure 410 except thatproprioceptive elements 536 used in place of proprioceptive elements 436have a height H1 that is less than the depth D of the hole 434 (i.e.,the annular recess) in which it is disposed, where both the height H1and the depth D are measured from the bottom of the hole 434. Stateddifferently, the proximal ends 42 of the proprioceptive elements 536 arerecessed relative to the surrounding portion of the midsole body 532 atthe proximal surface 22. In other embodiments, some of the holes 434 mayhave depths less than the heights of the proprioceptive elements thatthey surround. Because the proprioceptive elements 536 do not extendbeyond (i.e., above) the proximal surface 22 in the unloaded position ofFIG. 50 , greater translation along their central axes can occur beforepressure of an overlying foot inhibits further translation. Accordingly,the sole structure 510 can likewise experience greater articulation thansole structure 410.

FIGS. 53-60 illustrate another embodiment of a sole structure 610 withthe midsole 414 having the midsole body 432 as described with respect toFIGS. 41-47 . An outsole 516 is secured to the midsole body 432 in thesame manner as described with respect to outsole 416, except that theoutsole 516 has through-holes 634 that are aligned with and underlie theproprioceptive elements 436 such that the distal ends 38 of theproprioceptive elements 436 are exposed at the distal surface 483A ofthe outsole 516 and therefore serve as a portion of the distal surfaceof the sole structure 610. The sole structure 610 functions as describedwith respect to sole structure 410 except that, because the distal endsof the proprioceptive elements 436 are exposed, they may modify thetraction of the sole structure 610 both with respect to the ground andwith respect to an object such as a ball. For example, if theproprioceptive elements 436 are a material that is softer than thematerial of the outsole 416, they may increase the grip of the solestructure 610 on a ball.

FIGS. 59 and 60 show the sole structure 610 assembled in an article offootwear 612. The article of footwear 612 includes an upper 618 securedto the sole structure 610. The upper 618 may be any material ormaterials. The upper 618 terminates at a lower periphery 619 that issecured to a strobel 621. Both a portion of the lower periphery 619 andthe strobel 621 are secured to the proximal surface 22 of the midsolebody 432. The strobel 621 has holes 621A that are through-holes and arealigned with the proprioceptive elements 436 so that the proprioceptiveelements 436 protrude through the holes 621A.

The article of footwear 612 also includes a sockliner 631 overlying themidsole body 432 and the strobel 621. More specifically, the sockliner631 includes a foam layer 633 that has a distal surface 637 secured to aproximal surface 639 of the strobel 621. The sockliner 631 also includesan elastic layer 635 that has a distal surface 643 secured to a proximalsurface 645 of the foam layer 633. The sockliner 631 is shown in planview in FIG. 61 . The elastic layer 635 is also referred to herein as anelastic sockliner top layer. The elastic layer 635 overlies theplurality of proprioceptive elements 436 such that proximal ends 42 ofthe proprioceptive elements contact the distal surface 643 of theelastic layer 635. The elastic layer 635 is thinner and has greaterelastic stretchability than the foam layer 633. The midsole body 432 hasa plurality of midsole recessed surface portions 439. The outsole 516has a plurality of outsole protruded surface portions 441 and aplurality of outsole recessed surface portions 440. Each of theplurality of proprioceptive elements 436 has a side surface 443.

As shown in FIG. 60 , the foam layer 633 is disposed between the elasticlayer 635 and the midsole body 432. The foam layer 633 has holes 633Aaligned with the proprioceptive elements 436 such that theproprioceptive elements 436 extend through the holes 633A of the foamlayer 633 toward the elastic layer 635. Accordingly, the proprioceptiveelements 436 extend through the holes 621A of the strobel 621 andthrough the holes 633A of the foam layer 633 when interfacing with theelastic layer 635. With only the thin, flexible elastic layer 635between the foot-receiving cavity 17 and the proprioceptive elements436, proprioception is enhanced.

FIG. 62 is a flowchart of a method 710 of manufacturing an article offootwear, such as article of footwear 612. The method 710 may apply tofootwear that includes any of the sole structures 410, 510, 610, withthe exception of some portions of the method applicable only to solestructures 410 and 610. The method 710 begins with block 712, forming amidsole body such that the midsole body has annular holes at a proximalsurface of the midsole body, and annular recesses in a distal surface ofthe midsole body, with each annular recess encircling a different one ofthe annular holes from below and extending beyond a lowest extent of thedifferent one of the annular holes toward the proximal surface. Themidsole body also has a plurality of proprioceptive elements, eachproprioceptive element centered in a different one of the annular holes.Block 712 applies to the midsole bodies 432 and 532 as described herein.Forming the midsole body in block 712 may be by molding, such ascompression molding, or by 3-D printing.

Next, the method 710 moves to block 714, securing an outsole to thedistal surface of the midsole body so that the outsole lines the annularrecesses of the midsole body. For example, outsole 416 or 516 may beused. If outsole 516 is used, block 714 may include block 716, aligningthe through-holes 634 of the outsole with the proprioceptive elements436 such that the proprioceptive elements are exposed at a distalsurface 483A of the outsole, as described with respect to FIG. 55 .

The method then proceeds to block 717, securing an upper to a strobel,and then to block 718, securing the strobel to the proximal surface ofthe midsole body. Blocks 717 and 718 may be carried out, for examplewith upper 618, strobel 621, and midsole body 432 as described withrespect to FIGS. 59-60 . The strobel 621 has through-holes 621A thatalign with the plurality of proprioceptive elements 436. Accordingly,block 718 includes block 720, aligning the through-holes 621A of thestrobel 621 with the proprioceptive elements 436.

Next, the method moves to block 722, securing an elastic sockliner toplayer 635 to a proximal surface of the foam layer 633, with the elasticsockliner top layer 635 spanning across the holes of the sockliner 631.For example, elastic layer 641 is secured to foam layer 633 of thesockliner 631 as described.

Next, the method moves to block 724, securing a sockliner to theproximal surface of the strobel. For example, sockliner foam layer 633is secured to the strobel 621 in this manner. Additionally, block 724may include block 726, aligning the holes 633A of the sockliner (i.e.,holes 633A of sockliner foam layer 633) with the plurality ofproprioceptive elements 436 such that the proprioceptive elements 436protrude through the holes of the strobel 621 and the holes of thesockliner foam layer 633 when interfacing with the elastic sockliner toplayer 635.

“A”, “an”, “the”, “at least one”, and “one or more” are usedinterchangeably to indicate that at least one of the items is present. Aplurality of such items may be present unless the context clearlyindicates otherwise. All numerical values of parameters (e.g., ofquantities or conditions) in this specification, unless otherwiseindicated expressly or clearly in view of the context, including theappended claims, are to be understood as being modified in all instancesby the term “about” whether or not “about” actually appears before thenumerical value. “About” indicates that the stated numerical valueallows some slight imprecision (with some approach to exactness in thevalue; approximately or reasonably close to the value; nearly). If theimprecision provided by “about” is not otherwise understood in the artwith this ordinary meaning, then “about” as used herein indicates atleast variations that may arise from ordinary methods of measuring andusing such parameters. In addition, a disclosure of a range is to beunderstood as specifically disclosing all values and further dividedranges within the range. All references referred to are incorporatedherein in their entirety.

The terms “comprising”, “including”, and “having” are inclusive andtherefore specify the presence of stated features, steps, operations,elements, or components, but do not preclude the presence or addition ofone or more other features, steps, operations, elements, or components.Orders of steps, processes, and operations may be altered when possible,and additional or alternative steps may be employed. As used in thisspecification, the term “or” includes any one and all combinations ofthe associated listed items. The term “any of” is understood to includeany possible combination of referenced items, including “any one of” thereferenced items. The term “any of” is understood to include anypossible combination of referenced claims of the appended claims,including “any one of” the referenced claims.

Those having ordinary skill in the art will recognize that terms such as“above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may beused descriptively relative to the figures, without representinglimitations on the scope of the invention, as defined by the claims.

While several modes for carrying out the many aspects of the presentteachings have been described in detail, those familiar with the art towhich these teachings relate will recognize various alternative aspectsfor practicing the present teachings that are within the scope of theappended claims. It is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative and exemplary of the entire range of alternativeembodiments that would an ordinarily skilled artisan would recognize asimplied by, structurally and/or functionally equivalent to, or otherwiserendered obvious based upon the included content, and not as limitedsolely to those explicitly depicted and/or described embodiments.

What is claimed is:
 1. A sole structure for an article of footwear, thesole structure comprising: a midsole body having a proximal surface anda distal surface; and an outsole having a proximal surface and a distalsurface; wherein the proximal surface of the outsole is secured to thedistal surface of the midsole body; wherein the outsole includesexternal flex grooves at the distal surface of the outsole, and themidsole body includes internal flex grooves at the proximal surface ofthe midsole body; and wherein the internal flex grooves overlie and arealigned with the external flex grooves such that the sole structurearticulates at the external flex grooves both in dorsiflexion and inplantarflexion.
 2. The sole structure of claim 1, wherein the internalflex grooves border centerlines of the external flex grooves.
 3. Thesole structure of claim 1, wherein each external flex groove is borderedby two of the internal flex grooves.
 4. The sole structure of claim 1,wherein each external flex groove is tracked by two of the internal flexgrooves from above with a portion of the midsole body between the twointernal flex grooves directly overlaying the external flex groove. 5.The sole structure of claim 1, wherein at least some of the internalflex grooves close at a predetermined degree of dorsiflexion of the solestructure.
 6. The sole structure of claim 1, wherein at least some ofthe external flex grooves close at a predetermined degree ofplantarflexion of the sole structure.
 7. The sole structure of claim 1,wherein longitudinal centerlines of at least some of the internal flexgrooves extend in a transverse direction of the sole structure andlongitudinal centerlines of at least some of the internal flex groovesextend in a longitudinal direction of the sole structure.
 8. The solestructure of claim 1, wherein the external flex grooves and the internalflex grooves extend in a forefoot region and in a midfoot region of thesole structure and not in a heel region of the sole structure.
 9. Thesole structure of claim 1, wherein the internal flex grooves include afirst internal flex groove with a longitudinal centerline that tracks amedial peripheral edge of the midsole body in a forefoot region of thesole structure and a second internal flex groove with a longitudinalcenterline that tracks a lateral peripheral edge of the midsole body inthe forefoot region of the sole structure.
 10. The sole structure ofclaim 9, wherein the internal flex grooves further include a thirdinternal flex groove disposed between the first internal flex groove andthe second internal flex groove and with a longitudinal centerline ofthe third internal flex groove extending further forward than aforward-most extent of the first internal flex groove and furtherforward than a forward-most extent of the second internal flex groove.11. The sole structure of claim 10, wherein a rearmost extent of thethird internal flex groove is forward of a rearmost extent of the firstinternal flex groove and forward of a rearmost extent of the secondinternal flex groove.
 12. The sole structure of claim 10, whereinlongitudinal centerlines of at least some of the internal flex groovesextend in a transverse direction of the sole structure and intersect oneor more of the first, the second, and the third internal flex grooves.13. The sole structure of claim 12, wherein a foremost one of theinternal flex grooves with longitudinal centerlines extending in thetransverse direction of the sole structure intersects the third internalflex groove, does not intersect the first internal flex groove, and doesnot intersect the second internal flex groove.
 14. The sole structure ofclaim 12, wherein a rearmost one of the internal flex grooves withlongitudinal centerlines extending in the transverse direction of thesole structure intersects the first internal flex groove and the secondinternal flex groove and does not intersect the third internal flexgroove.
 15. The sole structure of claim 12, wherein multiple ones of theinternal flex grooves having longitudinal centerlines extending in thetransverse direction of the sole structure intersect each of the first,the second, and the third internal flex grooves.
 16. The sole structureof claim 1, wherein the external flex grooves include a first externalflex groove with a longitudinal centerline that tracks a medialperipheral edge of the sole structure in a forefoot region of the solestructure and a second external flex groove with a longitudinalcenterline that tracks a lateral peripheral edge of the sole structurein the forefoot region of the sole structure.
 17. The sole structure ofclaim 16, wherein the external flex grooves further include a thirdexternal flex groove disposed between the first external flex groove andthe second external flex groove and with a longitudinal centerline ofthe third external flex groove extending further forward than aforward-most extent of the first external flex groove and furtherforward than a forward-most extent of the second external flex groove.18. The sole structure of claim 17, wherein longitudinal centerlines ofat least some of the external flex grooves extend in a transversedirection of the sole structure and intersect one or more of the first,the second, and the third external flex grooves.
 19. The sole structureof claim 18, wherein a foremost one of the external flex grooves withlongitudinal centerlines extending in the transverse direction of thesole structure intersects the third external flex groove, does notintersect the first external flex groove, and does not intersent thesecond external flex groove; and wherein a rearmost one of the externalflex grooves with longitudinal centerlines extending in the transversedirection of the sole structure intersects the first external flexgroove and the second external flex groove and does not intersect thethird external flex groove.
 20. The sole structure of claim 18, whereinmultiple ones of the external flex grooves having longitudinalcenterlines extending in the transverse direction of the sole structureintersect each of the first, the second, and the third external flexgrooves.